Kaylor Test

Finished connecting everything today and took the vehicle for a quick run. The final results of the install went well.

The resulting test was dismal at best. I was not able to get past 25 mph and it did not feel like 600 amps were being feed into the motor. Heck it did not even feel like 200 amps were being fed into the motor. It did go and we did get some regen but the throttles are a bit crappy. I am using a TPS but I can't control it and adjust it like I can with the Synkromotive controller. I tried adjusting the controller to help with the throttle and it did help a bit. I set the controller for Speed, Balanced, and Torque. Neither netted any more than 25 mph. Oh I forgot to say that the voltage is 78 volts and the max operating voltage for this model is 90 volts before it goes into over voltage cutback. I am not sure why I am not getting the power to the motor. I had this sucker working before with the old controller and it pushed my Ghia to 62 mph. Something is still not quite right but I will keep hunting to see if I can figure out what is wrong. 

I am open to ideas. 

Pete :)

More Progress

Made some headway with the 66 Bug project. I got every thing connected except the throttle and made sure it all worked. I will have to take the motor out soon to check the flywheel. I am getting something out of balance or not tight. I can test once I get the throttle connected. I am going a different sort of setup with the throttle. I want the throttle in the vehicle.

I am also going to check out a nice Kelmark GT that is VW based. The nice thing is that I have a nice 69 Pan that is more or less ready to go and its the same year as the body. This pan has new pan halves in and Ghia disc brakes. I have nice rims that would look great. I'd leave it stock height for now. It would look killer if it was lowered.

Once again I am hunting for a killer project. Light weight and fun and fully enclosed. No open top. Much better for here.

Pete :)

A Bit More

Got a bit more done on the 66 Bug today. Been working on three projects at one time and no time to do them all. So a bit on each as time allows. Longer days allows for more to be done but we have been having spotty rain the past few days. Got rained out today. Short but ended my work. Oh well. I have the battery box in the rear seat area. Got the main cables strung from the box to the motor compartment. Motor is installed and getting the controller panel cleaned up. Made a few new cable connections to clean it up a bit. I will test in the next day or two.

This is a project that is using the old Kaylor Starter/Generator Motor setup with the software modified Kelly SepEx controller. It is a 72 volt 600 amp controller with modified software from Kelly. It has been a long time coming but the Regen Function will be tested on the road real soon. It has been tested on the bench and it works. But how well on the road is yet to be seen. No matter if it goes well or not I will post the results.

Brakes Installed

Brakes installed and old master cylinder removed. Boy, its amazing how much damage old leaked out brake fluid can do over time. I found out this evening that the rubber dust piece on the end of the master cylinder became caught between plunger and the end of the cylinder so not to allow the plunger to fully seat after you lift your foot from the brake. This over time allowed the fluid to leak but the fluid leaked inside the drivers compartment around the pedal assembly and onto the carpet. The carpet became saturated with half of the brake fluid from the reservoir and ruined the carpet, paint, pedal assembly. The fluid allowed the pan to begin rusting and the aluminum to start to corrode. It gummed up over time while sitting and just gummed up the works. It will be hell to clean but it should still be OK. I will need to replace the main hard line that goes through the vehicle that was just under the carpet and the brake line began rusting too. Not a safe thing. I may even have to replace the rear wheel cylinders on both wheels. I will also check the condition of the brake shoes in the back. It looks as though the brake line for the rear has been dry for quite some time. I am making good headway. Rear brakes come apart tomorrow. Ordering new carpet but it must be all clean and dry before I put any new carpet in the car. Then I will need to either get the seats recovered or replaced with different seats.

Pete :)

Brakes

UPS came late and I got my brakes from Airkewld this evening. It was like after 7pm that they arrived. I was told that the only thing that was not shipped was the lug nuts. Custom lugs are backordered. No problem. I can use the stock lugs for now. I can now get the front brakes done. Being a crappy customer service business I can say the quality is top notch. I got every thing correct the first time but it took a bit of time. They did custom make the rotors and hubs. They are made at the time of the order and very few are kept in stock. It is a small business and they are at the mercy of others. So I now have a new custom aluminum hub and custom rotors and willwood brake calipers. They are twin pistons one on each side and not too large. Plenty of stopping power and I can upgrade if needed. Too bad I can't get the old pads relined. I am still going to try. I will do some video of the install. It is raining pretty hard but I can do most of the work in the car port. I have two days to do the work including installing a new master cylinder and main line. New pedal assembly will be put in as will a cruiser pedal. I own an original cruiser pedal that I want to use. Now I get to use it.

I am so stoked that the parts finally arrived. I will get some photos in the morning and post them. Top notch all the way. I am a happy camper now. New bearings too. So off to the auto parts store for some quality wheel bearing grease.

Pete :)

Testing a Kaylor Motor/Adaptor Setup

Well we started once again the testing of the Kaylor Motor with ours software modified Kelly SepEx controller. We did a bench test in the last Ghia I had but sold because someone wanted it badly. We now have it installed in a 66 Bug. The bench test of the Regen function worked great. Now to street test this puppy. I did remove all that crappy black paint off the body of the motor. It is being prepared for painting.

Pete :)

A New Beginning

Here are a couple fun videos from the late 70's.